Modelling of air pressure effects in casting moulds

In the casting process, as a mould is filled with molten metal, air escapes through the vents. Air pressure in the mould cavity has serious effects upon the filling behaviour such as surface profile of the molten metal and filling time. In this project a computational model was developed for calculation of air pressure during the mould filling. A 3D single phase code based on the SOLA-VOF algorithm was used for the prediction of the fluid flow. The ideal gas assumption, conservation of mass equation and Bernoulli law were used for the calculation of air pressure. A new algorithm was developed to interpolate air pressure on the surface cells. The creation of air pressure was correlated with the sizes of the vents and their locations. An experimental test was designed to verify the modelling results. Comparison between the experimental data and simulation results has shown a good agreement.